Fiber optic based light ornament

A decorative light assembly comprises a plurality of optical fibers formed into a bundle having a length greater than one inch, the bundle having a first end for receiving light, and a second end that is fused for providing the received light as decorative illumination. The decorative light assembly is for use on, e.g., Christmas trees, windows, doors, etc.

BACKGROUND OF THE INVENTION

The invention relates generally to decorative lights and, more particularly, to fiber optic based decorative lights or ornaments.

Fiber optic Christmas trees are well known such as the one illustrated in U.S. Pat. No. 5,422,797 issued Jun. 6, 1995 to Shattan. In a fiber optic Christmas tree, individual optical fibers, or strands, are arranged on the tree to provide illumination. A light source is, e.g., located at the base of the tree. The light source can utilize a color-wheel, of one or more colors, so that the color of the light emitted by each strand changes over time.

Unfortunately, a portion of the consumer market does not care for fiber optic trees for the simple reason that they “lack light.” In other words, the intensity of the light output from each of the strands of optical fiber is dimmer in comparison to a more conventional Christmas tree utilizing electric light bulbs for illumination.

However, electric light sets for use as decorative items on, e.g., a Christmas tree, are not without their own problems. For example, although one can typically change their blinking frequency—one cannot change the overall color pattern once the electric lights are on the Christmas tree. In addition, and of even more concern, is their reliability—an electric bulb may fail. Indeed, depending on the design of the light set, a single electric bulb failure may cause a number of other bulbs to stop working. In this case, repair is somewhat problematic as one must first locate the failed bulb, which can be time-consuming. In addition, if a failure occurs while the light set is on the Christmas tree—intermixed with garland and other ornaments—it may be very inconvenient and difficult to repair. As a result of the reliability issue, common sense dictates that a string of bulbs be tested beforehand—again a labor and time-consuming effort. Regardless, spending the time to test an electric bulb set before placement on the Christmas tree does not ensure a bulb will not fail once arranged on the Christmas tree.

In view of the above, further improvements in decorative lighting arrangements would be desirable.

SUMMARY OF THE INVENTION

One aspect of the invention provides a decorative light assembly comprising a plurality of optical fibers formed into a bundle having a length greater than one inch, the bundle having a first end for receiving light, and a second end that is fused for providing the received light as decorative illumination. The fusing of the individual optical fibers at the second end of the bundle results in a mixing, or combining, of the light from each of the individual strands. Thus, the overall illumination from the fused end is brighter than the light from an individual strand and is comparable, if not better than, the illumination from an electric light bulb. In addition, the reliability of such a decorative light assembly is better than that of an electric light bulb since there is no bulb to fail.

In an embodiment of the invention, an ornament such as a Christmas tree is decorated with a number of optical bundles, each optical bundle having a fused end and an un-fused end. The Christmas tree includes a light source for coupling light into the un-fused end. Illumination, or decorative lighting, of the Christmas tree is provided by the light emitted from the fused ends of the optical bundles.

In other embodiments of the invention, other ornaments, objects or items, are decorated with optical bundles having a fused end and an un-fused end such as, but not limited to, a wreaths, flowers, windows, doors, etc.

In another embodiment of the invention, a decorative light set for providing decorative lighting comprises a light source and number of optical bundles for coupling to the light source and wherein each optical bundle has a fused end.

In another embodiment of the invention, a method of manufacturing an optical bundle comprises the steps of collecting a plurality of optical fibers together to form an optical bundle; and heating at least one end of the optical bundle to fuse, or weld, the individual strands together.

In another aspect of the invention, the fused end of the optical bundle is formed into a shape. For example, one shape resembles an electric light bulb.

DETAILED DESCRIPTION

FIG. 1shows a side view of a decorative light assembly in accordance with the principles of the invention. It should be noted that the illustrations shown in the FIGS. are not to scale and some illustrations, such asFIG. 1, have been exaggerated for purposes of description. In addition, other than the inventive concept, the elements shown in the figures are well known and will not be described in detail herein. Like numbers in each of the figures represent similar elements.

Optical bundle100comprises a number of optical fibers, or strands,120-1through120-N. Each strand is represented by a thick black line. As known in the art, a strand comprises a cladding material (not shown) surrounding a core material (not shown), which provides the medium for light propagation. In accordance with the inventive concept, any type, size, and composition of optical fiber may be used. In fact, different types of optical fibers may be used in the same optical bundle. For the purposes of this example, the number of optical fibers in an optical bundle may be in the range of 12 to 15, each strand on the order of 4 to 7 mils (thousandths of an inch) in thickness. It should be noted that the inventive concept is not so limited. For example, any number of optical fibers, N ≧2, may be used and the thickness of an optical fiber can be less than 4 mils or greater than 7 mils. Indeed, some or all of the optical fibers in a bundle may even differ in thickness. Surrounding these strands is a covering, or sheath105, represented by a dashed line. Sheath105can be, e.g., a colored tape, or paper wrapping. The color of sheath105may be selected to match the surroundings so as to hide, to an extent, the presence of optical bundle100. For example, if optical bundle100is to be arranged on a green-colored Christmas tree, the color of sheath105may be green to match that of the tree. It should be noted thatFIG. 1is a two-dimensional representation of optical bundle100in an x-y plane. While optical bundle100may be in the form of a ribbon and the strands arranged in just the x-y plane, a preferred embodiment arranges the strands of optical bundle100in three dimensions, e.g., along the z-axis shown inFIG. 1.

As illustrated inFIG. 1, optical bundle100has two ends—strand end110and fused end125. Strand end110comprises the individual optical fibers and illustratively extends beyond sheath105. Strand end110is coupled to a light source (not shown). At the opposite end of optical bundle100is fused end125. In fused end125each of the strands120-1to120-N are, in accordance with the principles of the invention, fused, or melted together. This “fusing” of each of the strands is represented by the crosshatched area of fused end125. The fusing of the individual optical fibers at the second end of optical bundle100results in a mixing, or combining, of the light from each of the individual strands. That is, the creation of a light combining region. Thus, the overall illumination from fused end125is brighter than the light from an individual strand (such as strand120-1) and is comparable, if not better than, the illumination from an electric light bulb (not shown). In fact, the white light available from an optical bundle may be crisper, i.e., appear “whiter” than the white light available from a conventional electric bulb. In addition, the reliability of such a decorative light assembly is better than that of an electric light bulb since there is no bulb to fail. As shown inFIG. 1, there may be a gap124between the fused end125and sheath105.

Turning now toFIG. 2, a front view of optical bundle100is shown. As illustrated inFIG. 2, optical bundle100extends in the z-axis and the strands120-1to120-N are fused together. As can be observed fromFIG. 2, optical bundle100comprises 14 strands (i.e., N=14). However, any number of fibers may be used in an optical bundle. Indeed, the amount of illumination from an optical bundle can be varied by having more or less strands, thinner or thicker strands, and/or combinations thereof.

An actual black and white image of an illustrative optical bundle in accordance with the principles of the invention is shown inFIG. 3.

Another illustrative embodiment is shown inFIG. 4. Optical bundle400is similar to optical bundle100ofFIG. 1except that one or more optical fibers are not a part of fused end425. In this example, two fibers,420-1and420-N, are not included in the plurality of optical fibers having fused end425. It should be noted that it is not required that these single strands emit any light, and they may be merely for decoration around fused end425.

Another illustrative embodiment is shown inFIG. 5. A Christmas tree300comprises a tree portion305supported by a light box350. The latter serves as a light source and may include a color wheel comprising one, or more, colors. In accordance with one aspect of the invention, arranged on tree300are a number of optical bundles, N, as represented by optical bundles310-1,310-2,310-3and310-N. Each optical bundle has a fused end, as represented by the enlarged ball shape (e.g.,311-1), and an un-fused end (not shown) disposed in light box350. It should be noted that other ornaments, and even other light ornaments (e.g., electric bulbs, single strand fibers) may also be decorated on tree300. The light source (not shown) of light box350provides light to the un-fused end of each optical bundle. The light is guided by each strand of an optical bundle towards the fused end. Upon reaching the fused end, the light from each strand combines to provide a level of illumination comparable to, if not brighter than, an electric bulb.

FIG. 6illustrates another view of Christmas tree300. The latter comprises a center post or metal pole303, around which each optical bundle (as represented by optical bundles310-1and310-2) is placed, weaved or wrapped. It should be noted that the optical bundles themselves may be further covered, or wrapped, to hide the presence of the optical bundles in the tree. The illustrative optical bundles ofFIG. 6are arranged along branches306and307. Along each branch an optical bundle may be wrapped or attached via a clip (not shown). However, the arrangement of the optical bundles on the tree can be in any fashion. As illustrated inFIG. 6, the un-fused ends of each optical bundle, e.g., un-fused end312-2, are disposed in light box350. The latter comprises a light source360(e.g., a bulb), a power source (not shown) and, optionally, a color wheel365. Light from light source360is emitted generally along the direction of arrow361to pass through color wheel365and then enter the un-fused ends of the N optical bundles as represented by un-fused end312-2. The light is guided by each strand of an optical bundle towards the fused end, as described above.

As noted above, any number of optical bundles may decorate a tree. The number will depend on the height of the tree and the intended decorative affect. For example, a tree with a height 8 feet may have on the order of 400 to 500 optical bundles as decoration. It can also have as few as one optical bundle. It should also be noted that a tree can come in one or more sections for ease of assembly. In addition, it can easily be observed fromFIGS. 5 and 6that optical bundles will come in different lengths. For example optical bundle310-2is shorter than optical bundle310-1. Consequently, optical bundle310-1will attenuate the light more than optical bundle310-2. This attenuation may become more noticeable in a taller tree (e.g., an 8 foot tree). As such, in taller trees it may be preferable to have multiple light boxes to compensate for this optical attenuation. For example, a bottom light box as illustrated inFIGS. 5 and 6for providing light to optical bundles on, e.g., the lower half of the tree, and another light box arranged towards the top of the tree for providing light to the remaining optical bundles. This is illustrated inFIG. 7where the length of optical bundle310-1has been shorted by coupling to light box390instead of light box350. Light box390may be coupled to the tree in any fashion.

Another embodiment in accordance with the principles of the invention is shown inFIG. 8. A wreath, or garland,605is decorated with one or more optical bundles, as represented by optical bundles610-1and610-2, which are coupled to a light source650.

In accordance with another aspect of the invention, attention should be turned toFIG. 9, which illustrates another embodiment. A light set package705comprises a number of optical bundles,710-1,720-2and710-N. Each optical bundle has a fused end (e.g., fused end711-1of optical bundle710-1) and an un-fused end (e.g., un-fused end712-1of optical bundle710-1). Light set package705also includes a light source750for coupling to the un-fused ends of the optical bundles. Light source750is similar to the light box described above and includes, e.g., a bulb, optional color wheel and a power source (or means for coupling thereto). The optical bundles of light set package705may be of differing lengths.

Such a light set package can be used to decorate not only trees and wreaths, but also other items, an illustrative embodiment of which is shown inFIG. 10. InFIG. 10, a window805is decorated with one or more optical bundles as represented by optical bundles810-1and810-2. The un-fused ends of the optical bundles are coupled to light source850. The latter is similar to the light box described above and includes, e.g., a bulb, optional color wheel and a power source (or means for coupling thereto).

An illustrative process for manufacturing an optical bundle in accordance with the principles of the invention is shown inFIG. 11. In step905a plurality of optical fibers or strands of approximately the same length are collected together to form a bundle. In step910, at least one end of the optical bundle is fused together. In step915, the optical bundle is wrapped. It should be noted that the optical bundle may be wrapped, e.g., in a sheath, before fusing. However, in such a case care should be taken with respect to that portion of the wrapping that is in close proximity—to what will be—the fused end of the optical bundle due to heat from the fusing, or melting, process.

FIGS. 12–14further illustrates step910ofFIG. 11. Turning first toFIG. 12, as a result of step905ofFIG. 11, an optical bundle5comprises a plurality of optical fibers, or strands,10-1to10-N. Optical bundle5is moved in the direction of arrow2towards a hot plate15(e.g., a steel plate heated to a temperature suitable to fuse, or melt, the fibers) Turning now toFIG. 13, end9of optical bundle5is pressed against hot plate15—thus melting or fusing that end of optical bundle5. As shown inFIG. 14, after, e.g., 1/16 of an inch of the optical bundle has been fused, optical bundle5is removed from contacting the surface of hot plate15. The resulting fused portion of optical bundle5—fused end25—may have a larger nominal size cross-section than the nominal size cross-section of the remainder of optical bundle5. This is illustrated inFIG. 14by the existence of flared portion26of fused end25. Illustratively, the flared portion26is on the order of 1/16 of an inch. This flared portion may be removed, e.g., cut-off, or may be left as is to ease the manufacturing process. Indeed, the flared portion can also be increased in size (by continued melting of that end of the bundle).

In another aspect of the invention, the fused end of the optical bundle is formed into a shape by, e.g., placing end9of optical bundle5ofFIGS. 12–14into a mold (not shown), which is then heated to fuse the strands therein into the particular shape. As end9of optical bundle5melts, optical bundle5is pressed into the mold until the mold is filled with melted material, at which point the process is terminated. Illustrative shapes may include, e.g., the shape of an electric light bulb as illustrated inFIG. 15by mold95. It should be noted that other methods of shaping the end may be used such as, but not limited to, filing, abrasion, etc.

Another embodiment of the invention is shown inFIG. 16. In this embodiment, a light combining region is formed—not by fusing or melting the individual strands—but by placement of the individual strands of end9of optical bundle5into a shaped cover85, e.g., a bulb shell (e.g., the form of a bulb) or lens.

Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. For example, the optical bundles may also decorate other ornaments or items, e.g., doors, doorways etc., etc. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims.