Abstract:
A portable hand-held apparatus for inserting one or more optical fibers into one or more insertion points in a flexible or semi-rigid panel having a uniform planar surface, positioning and adhering the fibers at the insertion points, playing out a pre-selected length of fiber and cutting the fibers at the selected length for collection in groups or bundles for attachment to one or more illumination devices.

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to a specialty hand-held optical fiber insertion apparatus that may be used to insert optical fibers into a flexible substrate, e.g., fabric, such as clothing, a hat, etc., or rigid or semi-rigid displays or signs. More specifically, the substrate is a semi-rigid base or planar surface for supporting the fiber optic display in the desired patterned array so that the ends of each optical fiber, arranged individually or in organized bundles, create the pre-determined and desired illuminated effect of the fiber optic display. The present invention allows the user, for the first time, to utilize a hand-held insertion apparatus to insert and arrange optical fiber ends individually for more intricate designs and displays of varying color lights, which require specialized attention to detail. 
     This type of technology has been virtually non-existent. U.S. Pat. No. 5,738,753 [Schwar et al.] teaches an automated machine for implanting optical fibers. The machine is comprised of a frame, for supporting a fiber inserter above a fiber insertion table, which pierces the interposed fabric (or semi-rigid, flexible) panel at a desired point of insertion and carries the optical fiber to the underside of the panel through an opening in the fiber insertion table for immersion into and removal from a liquid adhesive subsequently exposed to irradiation by ultra-violet light to cure and set the adhesive. This exposure to the ultra-violet light causes a change in state of the adhesive from the liquid to the solid state resulting in the permanent adherence of the optical fiber to the panel at the point of insertion. However, this machine fails to provide the kind of autonomy in design and hand-held convenience, i.e. freedom of motion, that the present invention provides. 
     In contradistinction, the present invention is a hand-held device, not a complex stationary machine with a pre-determined pattern for insertion of optical fibers, which allows the user greater freedom in design and attention to detail. Further, the present invention can insert the optical fiber from either side of the supportive panel or fabric and allows the user to secure the fiber to the substrate by hand-applying a quick cure adhesive, e.g., warmed air, specialized light, or heat cured adhesive. While the present invention may utilize ultraviolet light for further curation, it is not a necessary element, as is taught in the Schwar et al. patent. In fact, due to the nature of the present invention, air and heat adhesives are preferred over use of ultra-violet cured adhesives. Further, single or bundled optical fibers in an intricate or difficult design must be implanted by hand and to date, an apparatus has not been available to perform the required operation. Thus, the present invention overcomes this considerable setback by providing a novel and important contribution to the field. 
     Accordingly, it is an object of the present invention to provide a fiber inserting apparatus that is hand-held, portable, and allows the user the autonomy to create specialized patterns and illuminate more intricate designs with fiber optics than prior inventions have in the past. Further, it is also an object of the present invention to provide an apparatus for implanting a plurality of optical fibers manually and allowing the user to combine and sort the optical fibers into ordered bundles as desired. 
     It is another object of the present invention to allow the user to have ultimate autonomy in securing the optical fiber to the substrate once it has been inserted into the substrate and positioned appropriately. The user may then place the adhesive of choice on the outer surface of the optical fiber touching either the outer or inner surface of the substrate simultaneously and cure the adhesive such that the substrate and the optical fiber are securely adhered to each other. 
     Other objects will appear hereinafter. 
     SUMMARY OF THE INVENTION 
     The present invention provides a tangible solution to the considerable setbacks experienced with the prior inventions by providing an apparatus that allows the user to implant single or bundles of optical fibers by hand so that the user has greater autonomy in designing creative patterning for illuminated animations. Further, the fibers of the present invention may be secured in place by a hand applied quick-cure adhesive, thus allowing greater control over elaborate and complex designs. As a result, the user is capable of completing more intricate, free-hand designs than could be obtained from prior machines. 
     More specifically, the present invention is a hand-held apparatus for inserting one or more optical fibers into one or more insertion points in a flexible or semi-rigid panel having a uniform planar surface. The hand-held apparatus has an external housing for containing therewithin a drive means, a fiber feed means and a fiber severing means. The drive means includes an electrically operable and switchable motor drive coupled to the fiber feed means for operably controlling at least one or more segments of fiber feed rollers for feeding a length of optical fiber through one or more segments of a fiber guide means and into the fiber severing means. The fiber severing means is aligned with the fiber guide means to receive the length of optical fiber and pass the fiber through to a fiber insertion tool that is fixedly mounted to the front of the external housing and adjacent to the fiber severing means. The present invention further comprises a controller for selecting variable time periods in which said drive means is operably engaged to play out one or more pre-determined lengths of fiber corresponding to said time period. 
     The fiber insertion tool is aligned with the fiber severing means to receive the length of fiber and pass the fiber through a central hollow in the tool through a panel once the fiber insertion tool has pierced the panel at the desired point if insertion. Once the length of fiber has been positioned in the panel and a sufficient length of additional fiber for grouping and bundling has been played out from the fiber means, the fiber severing means is engaged. The fiber severing means is comprised of a severing blade attached to a severing handle, which when manually engaged, cooperate with each together to propel the blade into the fiber severing area to cut the fiber. 
     The present invention also proposes a preferred method for inserting one or more optical fibers into a flexible or semi-rigid panel having a uniform planar surface utilizing a hand-held portable optical fiber inserter comprising several steps. First, a length of optical fiber is fed into a fiber feed means of the optical inserter by moving through one or more segments of fibers guide means. The length of optical fiber is continuously fed through one or more segments of a second fiber guide means and into an aligned receiver of the fiber severing means and then into an aligned central hollow of the fiber insertion tool. The panel opposite the fiber insertion tool is then pierced with the fiber insertion tool at the desired point of insertion while carrying a length of the optical fiber through to the opposite side of the panel. A pre-determined length of fiber is played out that is sufficient for adhering the optical fiber to the panel and withdrawing the fiber insertion toll from the panel. Adhesive is applied between the optical fiber and the panel at one or more locations, which is cured causing a change in state of the adhesive permanently adhering to the optical fiber and the panel at the point of insertion. After the adhesive is cured, an additional length of optical fiber is played out such that the length is sufficient to gather the optical fiber with other optical fibers that may be sorted or grouped into one or more locations in a fiber sorting holder. The length of the optical fiber may further be played out in accordance with a variable control for selecting lengths of fiber to be played out from the portable inserter. Lastly, the length of the optical fiber is severed by engaging a fiber cutter in the fiber severing means for placing the cut end of the optical fiber in the fiber sorting holder. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     For the purpose of illustrating the invention, there is shown in the drawings forms that are presently preferred; it being understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown. 
     Referring now to the drawings in detail, where like numerals refer to like parts or elements, there is shown: 
     FIG. 1 is a side view of the optical fiber insertion apparatus of the present invention partially broken away to show the internal operating components. 
     FIG. 2 is an enlarged view of the feeding mechanism of the present invention taken along Line  2 — 2  of FIG.  1 . 
     FIG. 3 is an enlarged sectional view of the optical fiber severing apparatus of FIG.  1 . 
     FIG. 4 is a side view of the optical fiber insertion apparatus of the present invention partially broken away to show the internal operating components additionally showing the insertion of the needle and optical fiber through a flexible substrate. 
     FIG. 5 is a side view of the optical fiber insertion apparatus of the present invention partially broken away to show the internal operating components additionally showing the insertion of the needle and optical fiber through a flexible substrate. 
     FIG. 6 is a sectional view of the apparatus of the present invention showing the needle inserted through a flexible substrate with the optical fiber played out past the end of the needle. 
     FIG. 7 is a sectional view of the apparatus of the present invention showing the severing apparatus engaged and the apparatus withdrawn away from the inserted optical fiber. 
     FIG. 8 is a block diagram sectional view of the feed control of the apparatus of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The following detailed description is of the best presently contemplated mode of carrying out the invention. The description is not intended in a limiting sense, and is made solely for the purpose of illustrating the general principles of the invention. The various features and advantages of the present invention may be more readily understood with reference to the following detailed description taken in conjunction with the accompanying drawings. 
     Referring now to the drawings in detail, where like numerals refer to like parts or elements, there is shown in FIG. 1 the hand-held optical fiber insertion apparatus  10  of the present invention. Apparatus  10  is comprised of an exterior casing  12 , which is attached to insertion tool head  14  that contains insertion tool  16  through which optical fiber  18  is fed. Certain control mechanisms, which will be described below, extend through the casing  12  such as power switch  22 , power source cable connector  26  and fiber optic cutting or severing handle  32 . Internally, apparatus  10  includes fiber feed drive motor  24 , which is connected by spindle  20  to optical fiber feed section  48 , severing section  34 , and inner fiber feed tube  30 , which is attached to exterior casing via tube alignment supports  46  located along the length of tube  30 . 
     Insertion tool  16 , which is attached to insertion head  14 , is a needle-like rigid structure with a hollow central core, having a diameter large enough for fiber  18  to pass freely through and a sharpened end to penetrate flexible substrate  44 . As shown in FIG. 4, the insertion tool  16  is capable of puncturing flexible substrate  44  at the desired point. After insertion tool  16  has punctured substrate  44  completely, optical fiber  18  is fed through apparatus  10  starting from the rear end of the apparatus  10  (from reel  19 ) through fiber feed tube  30 . The diameter of tube  30  is slightly greater than that of fiber  18  so that fiber  18  may easily pass through and be directed forward by feed tube  30 . 
     To thread the insertion apparatus  10 , fiber  18  is manually pushed through tube  30  until it reaches a break between the front and back sections of fiber feed tube  30  and is directed into the fiber feed section  48 , as shown more specifically in FIG.  2 . The fiber feed section  48  of the present invention contains the elements the control area for the controlled feeding of fiber  18  through the hand held apparatus  10  and to insertion tool  16 . Spindle  20 , with cylindrical spindle roller  36  fixedly mounted around its upper portion, is attached between motor  24  and exterior casing  12  and is movably secured within a mating cylindrical recess  50 . Spindle  20  is responsive to actuation of the motor drive  24  initiated by power switch  22 . Attached parallel to spindle  20 , with spindle roller  36 , is a second vertically oriented cylindrical roller  28 , which is independent of motor  24 . The roller  28  is rotationally mounted on a second spindle  21 , which spindle is fixedly positioned in a parallel alignment with roller  36  (and spindle  20 ) in a second mating cylindrical recess  52  in the topmost portion of casing  12 . Cylindrical roller  28  is free to move in either a clockwise or counterclockwise direction depending upon the angular direction of spindle  20  and the direction of motion of motor drive  24 . While it is contemplated that motor drive  24  will provide switchably controlled movement in a single direction depending upon the engaging of power switch  22 , a reversing motor can be utilized with the appropriate switching controls. 
     Accordingly, as shown in FIG. 2, rollers  28  and  36  are just far enough apart so that an optical fiber  18  can pass though a small space between them, slightly compressing each roller  28 ,  36  resulting in frictional control over the longitudinal movement of the fiber  18  through the guide tube sections  30  and the insertion tool head  14 . The material used for rollers  28  and  36  may be the same, e.g. plastic, or they may differ for example in texture, to potentially create a lesser or greater amount of friction so that rollers  36  and  28  may interface with fiber  18  to more accurately move fiber  18  through the narrow space between them and into the forward section of feed tube  30 , and then into the insertion tool head  14 . 
     Accordingly, when low-voltage motor drive  24 , e.g. 9V, 12V, which is attached to a power source (not shown) through power cable  26  and connector  27 , is activated by pressing the push-button power switch  22 , spindle  20 , with associated spindle roller  36 , rotates in a clockwise direction (as shown). As spindle roller  36  rotates clockwise, it interfaces with the surface of parallel independent roller  28  and fiber  18 , causing roller  28  to rotate counterclockwise and together, with roller  36 , push optical fiber  18  through the fiber feed section  48  and continuously move fiber  18  forward into the next portion of feed tube  30  on the opposite side of rollers  28  and  36 , as shown in FIGS. 1,  4  and  5 . 
     As the fiber proceeds through fiber feed section  48 , it is directed through fiber feed tube  30 , fiber severing section  34 , insertion tool head  14  and eventually through the central hole of insertion tool  16  as shown by the dotted line in FIG.  5 . Fiber  18  is fed through the insertion tool to a pre-determined distance, as shown specifically in FIG.  5 . The fiber feed section  48  is then disengaged by releasing the push-button power switch  22  so that fiber  18  stops moving though apparatus  10 . The user then pulls insertion tool  16  out of and away from substrate  44  a short distance away from the point of insertion on the other side of the flexible substrate  44 . 
     The user then applies a liquid or semi-liquid adhesive around the area of optical fiber  18  and along the area of the substrate immediately adjacent to the fiber  18  by any suitable means that will circumferentially surround the optical fiber  18  and flow across the flexible substrate  44 . The adhesive may be applied in a liquid or semi-solid state and then a curing mechanism may be applied (if necessary) and the adhesive allowed to solidify. The adhesive types, in addition to those which cure simply by being exposed to air, may be selected from a group of adhesives which may be described as two-part epoxies, silicones, acrylics, and other plastic adhesives which are manufactured by 3M Companies, Dow Corning, Loctite, and others, as well as hot-melt and contact adhesives, all of which are intended to be applied in a liquid or semi-solid state and cured at the site of adherence. 
     More specifically, heat cured-adhesives are especially useful because they preserve the original light transmissivity characteristics of optical fiber  18  under controlled conditions. For example, a heat gun or other such controlled device may be used to cure the adhesive to fiber  18  at the point of insertion to flexible substrate  44 . The temperature of the heat desired to cure the adhesive without affecting the transmission characteristics of optical fiber  18 , is preferred to be in the temperature range of 200° F.-350° F., with a temperature of approximately 275° F. being more desirable. If the temperature of optical fiber  18  exceeds approximately 160° F., the transmissivity characteristics of the optical fiber will be altered due to partial melting of the fiber so it is not desirable for direct contact of the heat source with the optical fiber. 
     After the adhesive has been properly cured, the user engages the push-button power switch so that additional fiber  18  may be fed through apparatus  10 . Pre-determined lengths may be obtained as discussed more fully below. After the desired additional length of fiber  18  has been fed through apparatus  10 , the user can sever the fiber  18  using a fiber severing apparatus  40 . In order to sever fiber  18 , the user simply grasps severing handle  32 , which moves back and forth like a trigger within space  38 . By pulling handle  32  back, fiber severing apparatus  40 , with cutting blade  41 , is engaged and is pushed upwards into fiber severing area  42  of severing section  34 . The fiber severing area  42  is the space between the forward most end of fiber feed tube  30  and the rear-most portion of insertion tool head  14 . 
     Severing apparatus  40  has a cutting blade  41 , which when engaged by use of handle  32 , moves upward into severing area  42  and severs fiber  18 , as may be best seen in FIG.  3 . Opposite the feed tube  30  is an open conical recess which acts to guide the fiber  18  into and through the severing apparatus  40  so that the cutting blade  41  can sever the fiber  18  in a cylindrical space immediately forward of the conical guide, which cylindrical space approximates the outer diameter of the optical fiber  18 . 
     To disengage severing apparatus  40 , the user releases handle  32 , allowing it to return to its original position, which permits the disengaging of the severing apparatus  40  by lowering the cutting blade  41  from the severing area  42  and returning the blade into its original disengaged position within the severing section  34 , as shown in more detail in FIG.  3 . The user then simply pulls the optical fiber  18  from the front of the insertion apparatus  10  and removes the apparatus  10  away from the substrate area to release the cut fiber from insertion tool  16 . The user may then place the cut optical fiber  18  in a fiber sorting holder (not shown) for pre-sorted grouping or sequencing for later bundling of the optical fibers. 
     In summary, the manual process of inserting an optical fiber  18  into one or more points in a flexible substrate  44  can be described as follows with reference to FIGS. 5-8. The optical fiber  18  is manually fed into the rear of the insertion apparatus  10  until it impinges upon the fiber feed section  48 , and more particularly the feed rollers  28 ,  36 . The feed rollers  28 ,  36  are engaged by initiating the motor drive  24  by applying power through switch  22  so that the fiber  18  is operatively passed through the rollers  28 ,  36  and into the forward section of fiber guide  30 . With the optical fiber  18  loaded into the insertion apparatus  10 , the user may proceed to insert the optical fiber  18  at the desired point in the substrate  44 . 
     The insertion apparatus  10  is pushed through the substrate  44  at the desired point of insertion by passing the insertion tool  16  through the flexible substrate  44  a sufficient distance so that the insertion tool  16  extends outward from the substrate  44  on the reverse side as can be seen in FIGS. 5,  6 . Then the fiber feed section  48  is again engaged to feed the optical fiber  18  through the forward fiber guide  30 , passing through the fiber severing section  34 , and into the insertion tool head  14  and out the front of the insertion tool  16 . The fiber  18  is stopped by disengaging the fiber feed section  48  when the fiber  18  is extended outward a pre-determined distance from the needle or fiber insertion tool  16 . This distance may be in the range of approximately one (1) inch to several inches and would be dependent upon the skill of the user, the degree of flexibility of the substrate  44  and the desired positioning of the adhesive. 
     The insertion tool  16 , and the entire insertion apparatus  10 , is then withdrawn from the substrate  44  leaving only the optical fiber  18  extending through the substrate  44  as shown in FIG.  7 . An adhesive  54 , from the types described above, is placed at the desired location or locations, i.e. substrate front or back, or both, to secure the optical fiber  18  in place to the substrate  44  as depicted in FIG.  7 . The adhesive  54  may be allowed to cure, or a means for curing applied so that the adhesive  54  takes on the shape of a bead as shown in FIG.  7 . Then the fiber feed section  48  is re-engaged to feed an one or more additional lengths of fiber  18  outward from the insertion tool  16  so that the desired length of fiber  18 , sufficient to be grouped and bundled, extends from the front of the insertion apparatus  10 . 
     At this point the fiber severing section  34  is engaged to sever the optical fiber  18  by using the severing handle  32  to engage the cutting blade  41  as shown in FIG.  8 . The insertion apparatus  10  can then be pulled away from the fiber insertion area on the substrate  44  and the cut fiber can be placed in one or more groups for later bundling. The grouping may be nothing more than placing the cut fibers in a fiber sorting holder of any appropriate dimensions and design which can retain the fibers in their respective partial groupings until all insertions are completed and the bundling operation is undertaken. 
     To repeat the process for inserting another fiber  18 , the user simply inserts the insertion tool  16  into flexible substrate  44  in another point and activates the motor drive  24  by pressing the power switch  22 . Since the prior fiber  18  was cut at the fiber severing section  34 , forward of the fiber feed section  48 , the feed rollers  28 ,  36  simply feed the threaded optical fiber  18  through forward guide tube  30 , severing section  34 , and into insertion tool  16  so that the process may be repeated at the new point of insertion. 
     FIG. 8 depicts, in diagrammatic form, a controller for adjusting the fiber feed length which is passed through the fiber feed section  48  each time the feed drive motor  24  is engaged. Powering a multi-path delay circuit  25  is the drive motor switch  22  which has been described above. The other input to the multi-delay circuit  25  is the output of fiber feed length selector  23  which connection is represented by a single directional flow arrow which may provide either a continuous voltage level for a pre-selected period of time or a fiber length command represented by in digital form. In the event that the command is in digital form, the directional flow arrow is representative of either a serial or a parallel connection. Suitable electronics are contemplated to be utilized with either type of command signal for both the fiber feed length selector  23  and the multi-path delay circuit  25 . 
     The multi-path delay circuit  25  will engage a circuit path between drive motor switch  22  and fiber feed drive motor  24  for the length of time in which fiber feed length selector  23  requires a circuit path connection. This may be accomplished utilizing a silicon rectifier or silicon transistor trigger which produces continuous circuit connections between the drive motor switch  22  and feed motor  24 . Fiber feed length selector  23  may have a time period adjusting means in the form of a rotating switch which would engage different time delay circuits so that various and differing lengths of optical fiber  18  may be fed by feed motor  24  through fiber feed section  48 . This is so a substantially exact length of fiber  18  is played out from the insertion apparatus  10  in order for the fiber length to be substantially similar (if not identical) for the grouping and bundling to be performed later. 
     The adjustment of the time delay/fiber length selector of the fiber feed length selector  23  can be done manually by the operator to correspond with lengths of optical fiber  18  for purposes of grouping and bundling. The fiber feed length selector  23  may either be housed in the insertion apparatus  10  or may be interposed with an additional connector between the drive motor switch  22  and feed motor  24  so that when the switch  22  is depressed the feed motor  24  is energized in accordance with the time corresponding to the length of fiber  18  to be fed through the insertion apparatus  10 . In this manner the desired length of fiber  18  is played out from the insertion apparatus  10  so that each cut optical fiber has a substantially identical length for appropriate grouping and later bundling. 
     The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and, accordingly, the described embodiments are to be considered in all respects as being illustrative and not restrictive, with the scope of the invention being indicated by the appended claims, rather than the foregoing detailed description, as indicating the scope of the invention as well as all modifications which may fall within a range of equivalency which are also intended to be embraced therein.