Patent Application
20090093184
Not applicable.
Not applicable.
The present invention relates to fiber optics. More particularly, this invention relates to a method of integrating optical fibers into fabrics and sheet materials, the resulting structure of which can be incorporated into an item (e.g., a plush toy).
To integrate the optical fibers, they are made to pass through a sheet material, such as a fabric, in a desired arrangement. Ends of the optical fibers are flattened and enlarged such that they will not readily pass back through the sheet material. The ends are then covered with another sheet material that permits light to pass therethrough. The two sheet materials are secured together to hold the enlarged ends there between. The resulting structure can be readily incorporated into an item, such as a plush toy, to provide a light option to the item.
Further objects, features and advantages of the present invention over the prior art will become apparent from the detailed description of the drawings which follows, when considered with the attached figures.
The features of the invention noted above are explained in more detail with reference to the embodiment illustrated in the attached drawing figures, in which like reference numerals denote like elements, in which
Referring now to the drawings in more detail and initially to
The electrical components may also include a light source (not shown, such as an LED or other suitable light source) for selectively providing light to a light display 22. The light source may be coupled with proximal ends 24 of a plurality of optical fibers 26 via a coupler 28. The coupler 28 can hold the proximal ends 24 of the optical fibers 26 together in a bundle, thereby allowing a single light source to provide light to the plurality of optical fibers 26.
As is understood in the art, the optical fibers 26 carry light therethrough from the light source to distal ends 30 of the optical fiber 26 whereupon the light exits the distal end 30 of the optical fibers 26 and is visible to a user. The distal ends 30 of the optical fibers 26 may be spaced apart to create a desired visual pattern in the resulting light display 22.
In accordance with an aspect of the present invention, and to both obstruct the distal ends 30 of the optical fibers 26 from view when the light display 22 is not active and to prevent contact with the distal ends 30 of the optical fibers 26 by a user, the light display 22 is covered with an outer most fabric 32. Though not required, the outer most fabric 32 is preferably soft to the touch. As such, it is generally formed of a cloth, fabric or other textile. However, the outer most fabric 32 can be any thin material suitable for covering the light display 22. Preferably, the outer most fabric should be both capable of permitting light from the optical fibers 26 to pass therethrough during operation as well as being sufficiently opaque such that the distal ends 30 of the optical fibers 26 are not readily visible when the light display 22 is not activated.
The light display 22 may be formed as an assembly 34 that is separate from the plush toy 10, but which may be readily incorporated therein. The assembly 34 includes a first sheet 36 through which the optical fibers 26 are made to pass. The optical fibers 26 create small apertures 38 through the first sheet 36 as they pass therethrough. The apertures 38 are slightly larger than the distance around the optical fibers 26. Further, depending on the material that is used for the first sheet 36, the apertures 38 could provide a friction fit with regard to the optical fibers 26 passing therethrough. This would especially be the case if the first sheet 36 was a flexible foam sheet. It should be noted that the first sheet 26 can be any material suitable for carrying the optical fibers 26. Possible materials include fabrics, flexible foam sheets, textiles, papers, polymeric sheets, polymeric films, plastic sheets, plastic films, foils and any other thin sheet of material.
The assembly 34 also preferably includes a cover sheet 40 for covering the distal ends 30 of the optical fibers 26. While the cover sheet 40 could be the outer most fabric 32, the cover sheet 40, as illustrated the embodiment of
To keep the distal ends 30 from withdrawing through the apertures 38 in the first sheet 36, the distal ends 30 are preferably enlarged such that they have an outer periphery greater than a distance around the interior of the apertures 38. In an embodiment where the optical fibers 26 and the distal ends 30 both have circular cross sections, the outer diameter of the distal ends 30 are greater than the inner diameter of the apertures 38. The enlarged distal ends 30, being larger than the apertures 38, prevent the distal ends 30 from passing through the first sheet 36 back into the interior of the body portion 12 of the plush toy 10. The distal ends 30 of the optical fibers 26 can be enlarged by a number of different methods. One method is to heat the end of the optical fibers. Another method is to place a separate item on the end of the optical fiber. The item is coupled with the end of the optical fibers 26 and permits light to pass therethrough. While it is contemplated that the distal ends 30 of the optical fiber 26 will be enlarged after the optical fibers 26 are passed through the first sheet 36, it is within the scope of the present invention to provide optical fibers 26 that already have enlarged distal ends 30 and subsequently insert the proximal ends 24 through the first sheet 36 until the distal end 30 abut the outer surface 44 of the first sheet 36.
In one embodiment, the assembly 34 also includes an inner sheet 46 that covers a portion of the optical fibers 26 as they exit the apertures 38 on a side opposite the distal ends 30. In one embodiment, the inner sheet 46 may take the form of a tape having an adhesive on an inner surface 48 thereof. In this embodiment, the inner sheet 46 would be adhered to the optical fibers 26 and an inner surface 50 of the first sheet 36 to help fix the relationship of the optical fibers 26 with respect to the apertures 38. While the inner sheet 46 may be transparent, it is preferably either opaque or translucent. As with the cover sheet 40, the inner sheet 46 need not be adhered to the first sheet 36 but can be coupled therewith by other known means, such as by sewing.
Many variations can be made to the illustrated embodiment of the present invention without departing from the scope of the present invention. Such modifications are within the scope of the present invention. For example, the cover sheet 40 could be eliminated and the first sheet 36 could be attached directly to the outermost fabric 32. Similarly, the inner sheet 46 could be eliminated and the optical fibers could be exposed to contact with the batting 14. However, it has been found beneficial for manufacturing and assembly purposes to create the assembly 34 consisting of tape 40 and 46 on opposite sides of the first sheet 36 to secure the optical fibers in relation to the first sheet 36. The pre-assembled assembly 34 can then be readily incorporated into a plush toy 10. Other modifications would be within the scope of the present invention.
From the foregoing it will be seen that this invention is one well adapted to attain all ends and objects hereinabove set forth together with the other advantages which are obvious and which are inherent to the structure. It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the invention.
Since many possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative of applications of the principles of this invention, and not in a limiting sense.
