Abstract:
A fiber stacking or aligning apparatus is described. In an embodiment, the apparatus includes a first component and a second component. The first component is configured to permit the introduction of a plurality of fibers into an opening that defines a through hole through the first component. The second component is rotatably coupled to the first component, wherein the second component is configured to permit the introduction of the plurality of fibers that have passed through the through hole into an area in the second component that includes an alignment surface which limits the travel of the plurality of fibers so as to align the plurality of fibers, wherein the second component is further configured to be rotated away from the aligned plurality of fibers to expose the aligned plurality of fibers without disturbing them.

Description:
RELATED APPLICATIONS 
   This application claims the benefit of U.S. Provisional Patent Application No. 60/637,349, filed Dec. 17, 2004, which is hereby incorporated by reference in its entirety. 

   TECHNICAL FIELD 
   The disclosed embodiments relate to devices and methods for arranging fibers and fiber-like materials for manipulation in a manufacturing process. 
   BACKGROUND OF THE DISCLOSURE 
   Fine fibers or fiber-like materials, such as hairs, are used as components in many assemblies, including fishing flies for example. Fine fibers are also used to create artworks or to embellish fabric. In order to arrange the fine fibers for attachment to a fishing fly or fabric, etc., it is often necessary to arrange the fibers. For example, in many types of fishing flies, groups of animal hairs are arranged for attachment to a fishing hook. The hairs might be intended to look like an insect wing, for example. In order to look and behave properly, the hairs should be arranged in a bunch with all of the roots at one end, and all of the tips aligned. The bunch of hairs is then attached to the fishing hook by tying the root end of the bunch to the hook. The bunch can be tied so that the aligned hair tips fan out on one side of the hook (to look like a wing), or arranged to fan out all around the hook, etc. 
   Convention hair stackers exist for arranging bunches of hairs such that the tips are all aligned and the root end can be grasped to tie the bunch to a hook. Conventional hair stackers have significant disadvantages, however. For example, conventional hair stackers require the bunch of hairs to be shifted from one hand to the other during the process of extracting the bunch from the stacker, which takes time and usually causes the bunch to become disturbed. Another disadvantage is that the alignment of the hair tips cannot be observed unless one of the two independent parts of the conventional hair stacker is removed to visually check the alignment. This also takes time and causes disturbance of the bunch. Yet another disadvantage is that in the process of removing one of the two independent parts of the conventional stacker to shift the bunch of hairs from hand to hand in preparation for tying the bunch, one part of the conventional hair stacker usually must be set down and may become lost. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIGS. 1–9  are diagrams of a fiber stacker apparatus according to an embodiment. 
       FIG. 10  is a flow diagram of a method for stacking hairs or fibers according to an embodiment using the apparatus of  FIGS. 1–9 . 
       FIGS. 11 and 12  are dimensioned schematic diagrams of components of the apparatus of  FIGS. 1–9  according to an embodiment. 
   

   DETAILED DESCRIPTION 
   Embodiments of the invention include a fiber or hair stacker that overcomes the disadvantages of the conventional hair stacker and is easier and faster to use than the conventional hair stacker. 
   The embodiment of the figures as described herein is one example of the invention, and various modifications, including size variations for example, are within the scope of the invention. As used herein, the terms “hair” and “fiber” are used interchangeably, but in general the embodiments described are suitable for stacking or aligning any group of substantially hair shaped objects that have small diameters in proportion to their lengths. 
     FIGS. 1–9  are diagrams that show various views of a hair stacker apparatus  100  according to an embodiment.  FIGS. 1–4  show the hair stacker apparatus  100  in a closed position.  FIGS. 5–9  show the hair stacker apparatus  100  in an open position. 
   As shown in  FIG. 1 , the hair stacker apparatus  100  includes a top  102  and a bottom  104 . The top  102  and the bottom  104  are coupled by a fastener  108 , which is a screw in one embodiment. The top  102  is coupled to the bottom  104  such that a bottom surface of the top  102  is in proximity to a top surface of the bottom  104 . Various embodiments also include a washer (not shown) on the fastener  108  between the top  102  and the bottom  104 . The top  102  and the bottom  104  rotate with respect to one another about the fastener  108 . The rotation of the top  102  and the bottom  104  with respect to one another is limited by protruding edges  106  and  112 . The protruding edge  106  forms a lip that is located on the top  102  in proximity to the bottom surface of the top  102 . The protruding edge  112  forms a lip that is located on the bottom  104  as shown in  FIG. 3  in close proximity to a top surface of the bottom  104 . The protruding edge  102  includes a swing arc  107  (as shown in  FIGS. 5 and 11C ) for clearance to accommodate rotation of the top  102  and the bottom  104  with respect to each other. 
   The separation of the top  102  and the bottom  104  is exaggerated in the figures for the purpose of illustrating features such as the protruding edges  106  and  112 , which are not visible when the top  102  and the bottom  104  are more fully closed. 
     FIG. 2  is a diagram showing the bottom  104  and the top of fastener  108  sitting in a countersunk hole into which the fastener  108  is inserted for assembly of the top  102  to the bottom  104 . 
     FIG. 3  is a diagram showing the side of the hair stacker apparatus  100  opposite the side shown in  FIG. 1 . The bottom  104  includes an area  110  for accommodating fibers or hairs. A bunch of fibers  101  is show inside the area. A protruding edge  112  limits the rotation of the top  102  with respect to the bottom  104  by coming into contact with the protruding edge  106  of the top  102 . The separation of the top  102  and the bottom  104  is exaggerated in the figures for the purpose of illustrating features such as the protruding edges  106  and  112 , which are not visible when the top  102  and the bottom  104  are more fully closed. 
     FIG. 4  is a diagram showing the top surface of the top  102  and an opening  114 . In one embodiment the opening  114  is circular, and the inner diameter of the circle defines a through hole in the top  102 . Hairs or other fibers  101  are inserted tip first into the opening  114 . The tips of the hairs  101  are aligned by tapping the apparatus  100  to cause the tips of the hairs to rest on an alignment surface  111  of the area  110  (see  FIG. 3 ). This “stacks” the hairs in a bunch with uniformly aligned tips in preparation for attaching the bunch to, for example, a fish hook. The opening  114  has a beveled edge, or chamfer  116  for easier insertion of hairs into the opening  114 . 
   After the hairs are stacked as previously described, the apparatus  100  is opened to access the stacked hairs by rotating the top  102  and/or the bottom  104 .  FIGS. 5–9  are diagrams of an open apparatus  100 .  FIG. 5  is a diagram showing the bottom  104  rotated around the fastener  108  in the direction shown by arrow  103 . 
     FIG. 6  is a diagram showing another view of the bottom  104  rotated to the same position with respect to the top  102  as shown in  FIG. 5 . 
     FIG. 7  is a diagram showing a different view of the apparatus  100  with the top  102  and the bottom  104  in the same relative positions as in  FIGS. 5 and 6 .  FIG. 7  shows the opening  114  through which hairs are inserted, and also shows the surface  111  of the area  110  on which the tips of the hairs rest. The area  110  is defined by a curved wall  113  which, in a closed position of the apparatus  100 , accommodates hairs or fibers inserted through the opening  114 . In one embodiment, the opening  110  as defined by the curved wall  113  is larger than the through hole defined by the opening  114  in the top  102 , and is aligned approximately coaxially with the through hole defined by the opening  114  in the top  102 . 
     FIG. 8  is another view of the apparatus  100  with the top  102  and the bottom  104  in the same relative positions as in  FIGS. 5 and 6 .  FIG. 8  shows a different view of the area  110  and the curved wall  113 . 
     FIG. 9  is another view of the apparatus  100  with the top  102  and the bottom  104  in the same relative positions as in  FIGS. 5 and 6 .  FIG. 9  shows the protruding edges  106  and  112  in cross-section in an open position of the apparatus  100 . The edges  106  and  112  stop against each other in a closed position of the apparatus  100  and prevent rotation of either the top  102  or the bottom  104  in one direction. 
     FIG. 10  is a flow chart of a method  1000  of stacking or aligning hairs using embodiments of the apparatus as described herein. A bunch of hairs is inserted tip first into the opening of the top of the apparatus, when the apparatus is in a closed position, as shown at  1002 . At  1004 , the apparatus is tapped with the alignment surface downward to stack or align the tips of the hairs against the alignment surface. At  1006 , the closed apparatus is turned to view the hair tips through the opening in the bottom  104 . As shown at  1008 , it can then be determined whether the hairs are satisfactorily aligned. That is, it can be determined whether all or almost all of the hairs tips are resting on the alignment surface. If the hairs are not satisfactorily aligned, the tapping Repeat tapping process is repeated at  1010 . 
   The bunch of hairs is removed from the apparatus by opening the apparatus and grasping the bunch by the tips using one hand, as indicated at  1012 . The apparatus is opened by rotating the top  102  or the bottom  104  such that the bottom  104  swings away from and exposes the aligned bunch of hairs. As shown at  1014 , the bunch of hairs is then attached to an assembly while still being grasped using the same hand that removed the bunch from the apparatus. 
   If it is desired for some reason to grasp the root end of the bunch of hairs and leave the tip end free, this is also easily done by grasping the root end protruding from the opening  114  and removing the bunch of hairs. The apparatus  100  does not need to be opened in this case. 
   The apparatus  100  does not need to be disassembled in the normal course of use for stacking hairs or fibers. Therefore, there is never a danger of mislaying a part of the apparatus  100 . 
     FIGS. 11A ,  11 B,  11 C,  12 A,  12 B, and  12 C are more detailed dimensioned diagrams of one embodiment of the invention, and are not intended to be limiting. Various dimensions and features other than those shown may also be used to make a hair or fiber stacker as described and claimed herein. Any suitable materials may be used to manufacture the apparatus, including but not limited to, plastic, aluminum, and other metals or alloys. The embodiments are described using hairs as an example of a fiber to be stacked, but any other fiber can be similarly stacked using the embodiments. The dimensions shown are an example of an embodiment that is suitable for stacking animal hairs for fishing flies, but embodiments are not so limited. For example, larger dimensions can be used to accommodate larger fibers. Also, the overall dimensions shown are comfortable for an average human hand to hold and manipulate. If it was desired to design an apparatus for unusually large or small hands, the dimensions can be adjusted accordingly. The invention is thus defined by the claims below.