Methods and systems for marring fiber optic substrates

Methods and systems for marring the surface of a fiber optic substrate by pressing a length of the substrate against an elongate support with at least one roller and causing relative lengthwise movement between the roller and support with the roller pressing the substrate against the support and the roller rolling along the substrate. One of the roller and support may have an abrasive surface for marring the substrate during such relative lengthwise movement between the roller and support. Alternatively, the abrasive surface may be on a sheet supported by the support.

FIELD OF THE INVENTION

This invention relates to various methods and systems for marring the surface of fiber optic substrates to create fiber optic illuminating devices.

BACKGROUND OF THE INVENTION

Fiber optic substrates can be made into illuminating devices by marring or abrading (hereinafter collectively referred to as “marring”) the surface of the optical fibers at various points along their length to cause a portion of the light applied to one or both ends of the optical fibers to be emitted from the marred surface areas. Such illuminators may be used for example for display lighting, back lighting, front lighting and/or ornamental lighting and the like.

Increased surface marring results in increased light emission. Accordingly, the intensity of the light emitted along the length of the substrates can be varied by varying the density or aggressiveness of the surface marring.

It is generally known to mar fiber optic substrates by stamping, machining, molding, sandblasting or rolling fiber optic substrates to create a desired illumination pattern on the surface of the substrates. However, there is a continuing need for other effective methods and systems for marring fiber optic substrates to create fiber optic illuminators having a desired illumination pattern.

SUMMARY OF THE INVENTION

The present invention relates to various methods and systems for marring fiber optic substrates to create relatively inexpensive illuminators having a desired illumination pattern.

In accordance with one aspect of the invention, the system includes at least one roller for pressing a length of fiber optic substrate against an elongate support while causing relative movement between the roller and support lengthwise of the support with the roller rolling along the substrate. At least one of the roller and the support supports or has an abrasive surface thereon for marring the substrate during such relative lengthwise movement between the roller and support with the roller in pressing and rolling engagement with the substrate.

In accordance with another aspect of the invention, the pressure between the roller and support may be varied during such relative lengthwise movement to vary the marring of the substrate.

In accordance with another aspect of the invention, the rate of relative lengthwise movement between the roller and support may be varied with variations in pressure between the roller and support to vary the marring of the substrate.

In accordance with another aspect of the invention, a non-uniform or variable abrasive surface may be provided on the roller. Also, the roller may be indexed to a predetermined rotational orientation and the roller and support positioned in a predetermined relative lengthwise starting position prior to causing the roller to press the substrate against the support and moving the roller and support lengthwise relative to one another to obtain an easily repeatable marring pattern on the substrate.

These and other objects, advantages, features and aspects of the invention will become apparent as the following description proceeds.

To the accomplishment of the foregoing and related ends, the invention, then, comprises the features hereinafter more fully described and particularly pointed out in the claims, the following description and the annexed drawings setting forth in detail certain illustrative embodiments of the invention, these being indicative, however, of but several of the various ways in which the principles of the invention may be employed.

DETAILED DESCRIPTION OF THE INVENTION

Referring now in detail to the drawings and initially toFIG. 1, there is schematically shown a system1in accordance with the invention for marring the surface of optical fibers2of a fiber optic substrate3for causing light applied to one or both ends of the optical fibers to be emitted from the marred surface areas thereof. The substrate3may be comprised of a plurality of such optic fibers2, only one of which is shown, adhered to a suitable backing4which may for example be a plastic, generally reflective, sheet. The surfaces of other light guides including fiber optic rods and transparent plastic films, sheets or plates may also be marred in accordance with the invention similar to fiber optic substrates to create illuminators having a desired illumination pattern.

System1includes an elongate support5having a generally flat support surface6for supporting a length of the fiber optic substrate3thereon. One or more rollers8supported for example by an actuator9or other suitable mechanism is movable toward and away from the support5for releasably pressing the substrate against the support surface during relative lengthwise movement between the support5and roller8to mar a surface of the substrate as described hereafter.

In the embodiments shown inFIGS. 1-4,8and9the support5is mounted for lengthwise movement relative to the roller8, whereas in the embodiments shown inFIGS. 5-7, the support5is fixed and the roller8is mounted for lengthwise movement relative to the support as well as for movement toward and away from the support. In any case, the roller8may be rotated as by means of a suitable drive motor10to cause the roller to roll along the substrate3at the same rate of relative lengthwise movement between the roller and support so there is no relative rotational movement between the roller and substrate during marring of the substrate. To that end, the drive motor10for rotating the roller8and the various drive mechanisms11or12for causing lengthwise movement of the support relative to the roller as schematically shown inFIGS. 1 and 8or for causing lengthwise movement of the roller relative to the support as schematically shown inFIG. 5may all be commonly controlled by a programmable computer/controller15or the like. Similar type drive mechanisms and controls may of course also be included in the systems shown in the various other drawing figures.

The surface16of roller8may be roughened or serrated or covered with a diamond coating or grit sandpaper or other suitable abrasive material to provide an abrasive surface17thereon for marring the substrate3during relative lengthwise movement between the roller and support with the roller pressing the substrate against the support as the roller rolls along the substrate as schematically shown inFIGS. 1,5and9. Alternatively, the abrasive surface17may be on the support surface6as schematically shown inFIGS. 2 and 6or on an abrasive sheet18that may be interposed between the substrate and the support as shown inFIGS. 3 and 7or between the roller and the substrate as shown inFIG. 4to mar the substrate during such relative lengthwise movement. When the roller surface or support surface is not the abrasive surface, these surfaces may be hard or have a deformable cover. Regardless of where the abrasive surface17is, the surface of the fiber optic substrate to be marred thereby must be exposed to the abrasive surface17during the marring operation. Otherwise, the systems shown in the different drawing figures are substantially the same and accordingly the same reference numbers are used to designate like parts.

If the substrate3is marred uniformly, the amount of light emitted along its length will be greater near where the light enters the substrate and less further away from where the light enters the substrate. Therefore, if uniform lighting is desired, there is a need to mar the substrate unevenly (i.e., more aggressively away from where the light enters and less aggressively near where the light enters the substrate). In order to produce a specific illumination pattern, the pressure between the roller and the support surface may be varied by the computer/controller15during such relative lengthwise movement between the roller and support surface. Likewise, the rate of relative lengthwise movement between the roller and support surface may be varied by the computer/controller15along with the pressure to produce a specific illumination pattern. Also, the roller8and support5may be moved back and forth lengthwise relative to one another with the roller pressing the substrate against the support surface6as many times as desired to more aggressively mar the substrate to produce a specific illumination pattern. Further, the abrasive surface17may have a variable pattern to produce a variable illumination pattern on the substrate.

If a non-uniform or variable abrasive surface17is provided on the roller8, the roller may be indexed to a predetermined rotational orientation and the roller and support located in a predetermined lengthwise starting position relative to one another before the roller is moved toward the support to press the substrate against the support surface as schematically shown in FIG.8. This has the benefit that when the roller and support are moved lengthwise relative to each other as schematically shown inFIG. 9with the roller pressing the substrate against the support surface, a desired illumination pattern may be obtained that may easily be repeatedly formed on any number of substrates as desired.